Process of and apparatus for molding shaped articles such as containers for milk, cream, jam, and the like from fibrous pulp



W. ROY PROCESS OF AND APPARATUS FOR MOLDING SHAPED ARTICLES SUCH ASCONTAINERS FOR MILK, CREAM, JAM, AND T LIKE FROM FIBROUS PULP Filed Aug1919 6 Sheets-Sheet l June 29 1926.

W. ROY

PROCESS OF AND APPARATUS FOR MOLDING SHAPED ARTICLES SUCH AS CONTAI-NERSv FOR MILK, CREAM, JAM, AND THE LIKE FROM FIBROUS PULP Filed Au t 29,1919 6 Sheets-Sheet 2 FIG 6 June 29 1926. 1,590,956

W. ROY PROCESS OF AND APPARATUS FOR MOLDING SHAPED ARTICLES SUCH ASCONTAINERS FOR MILK, CREAM, JAM, AND THE LIKE FROM FIBROUS PULP FiledAugus? 9 6 Sheets-Sheet 5 June 29 ,1926. 1,590,956

. w. ROY PROCESS OF AND APPARATUS FOR MOLDING SHAPED ARTICLES SUCH ASCONTAINERS FOR MILK, CREAM, JAM, AND THE LIKE FROM FIBROUS PULP FiledAugust 29, 1919 6 Sheets-Sheet 4 June 29 1926.

W. ROY A PROCESS OF AND APPARATUS FOR MOLDING SHAPED ARTICLES SUCH A FORMILK, CREAM, JAM, AND THE Filed August 29, 1919 S CONTAINERS LIKE FROMFIBROUS PULP 6 Sheets-Sheet 5 FIGIS June 29 1926. 7 1,590,956

W. ROY PROCESS OF AND APPARATUS FOR MOLDING SHAPED ARTICLES SUCH ASCONTAINERS FOR MILK, CREAM, JAM, AND THE LIKE FROM FIBROUS PULP FiledAug 1919 6 Sheets-Sheet 6 Patents June 29,1926. 1,590,956

UNITEDSTATES PATENT OFFICE.

WILLIAM ROY, OF ADELPHI, LONDON, ENGLAND.

PROCESS OF AND APPARATUS FOR MOLDING SHAPED ARTICLES SUCH AS CONTAIN-ERS FOB MILK, CREAM, JAM, AND THE LIKE FROM FIBROUS PULP.

Application filed August 29, 1919, Serial No. 320,657, and in GreatBritain November 13, 1918. (GRANTED UNDER THE PROVISIONS OF THE ACT OFMARCH 3, 1921, 41 STAT. L, 1313.)-

This my invention consists in a process forated metal, or otherpermeable material, of and means for producing and making that forms thetop or face of the mold and receptacles or other like articles of paperor covers itsentire surface. Fitted to each mold paper felt (ashereinafter described) by is a removable frame light and rigid, called 55 hand, from liquid non-viscous fibrous pulp the deckle, having arebated edge which acas used in the manufacture of hand made curatelyfits over the mold frame and forms paper in a vat, by means of molds, inother a raised edge above the top or face of the forms than flat orplane sheets, and partioupermeable material, all the way round. Thelarly in the production of an integral piece vatman or operator graspingthe mold firm- 60 of hand-made paper, felt, or the like of the 1ybetween his extended arms dips it with form of a hollow truncated cone,bottle a sloping motion into the moving pulp in shape, rectilinear, orother hollow raised the vat, which flowing over forms a regular shape,preferably tapering inwards towards stratum of pulp on the upper orpermeable the top, and having a flat flanged portion at surface of themold. As the mold is lifted 65 the base. Furthermore each integral pieceor out of the pulp the water begins to drain sheet may have a series ofsuch like shapes through the perforated surface, a partial raised uponthe base, provision being made vacuum generates and draws the stratum toto enable a plurality of shapes to be molded the surface of the mold,and at or about this simultaneously. stage the vatman by a shaking andtwisting 7 The word paper-felt is used in this specmotion given to themold and its contents ification in the sense of the felting or matweavesand interlaces the fibers, and finally ting effects upon the fibers ofthe fibrous produces upon the surface of the mold bepulp, resultinzrfrom the movements of the tween the edges of the upper frame, a sheetvatmans hands guiding the hand mold as of paper. This wet film of paperproduced 7 hereinafter described. I now requires to be drained ofsurplus mois- The advantages of this my invention are ture andstrengthened by' sizing, and these that such receptacles are producedwithout two objects are attained by the. employment side seams and thoseof cup shape are seamof couching felts, these being pieces of woolless,consequently the receptacles made by en cloth of a size larger than themold itself. 80

my process are aseptic and hygienic. Fur- The wet film is transferredfrom the mold ther as only the best papers are made by to a couchingfelt by turning the mold over hand, the best materials being necessarilydownwards and is laid or couched'upon the selected, carefullyfree of anydirt, the refelt to which it readily adheres on contact. sultingsuperiority of this-hand-made paper Another couching felt is placed overthe as as a food container, in the essential qualities film and theoperation continues as regards of purity, strength, and durability, isat once transferring of laying paper and felt alterevident, inappearance and handling, when nately until a certain number of felts arecompared to a machine made paper. No piled upon an equal number of wetfilms. mechanical device or machine can or will A number of thesealternate layers of felts 00 40 adapt itself to the changing conditionsin and films are now taken together and passed my hand process, andperform similar and through a tub of size and drained. After equal work.which the sheets of paper may be safely The known primitive process ofmaking handled and removed from the couching felts paper, by hand, iscarried out in the handand dried. 95

mill in a vat of prepared pulp, and by According to my improved process,paper, means of a hand-mold. This hand mold conor paper felt is producedand made by hand sists of a wooden frame, light and rigid, of ashereinbefore described but in other forms a size of the required sheetof paper. Transthan flat sheets in such shapes as receptacles, versewires passing through and over light containers and other articles, bymeans of 100 wooden bars help to keep the frame taut, hand molds asdescribed above, of gauze and form a support for the gauze wire,perwire, perforated metal, or other permeable is open at the bottom (asdescribed) during the process, and the drainage flow interconnected withthat eflect, I provide a' detachable tube or ,series of tubes at anyconvenient part or parts of the mold, (the optional point of connectiondoes not alter 5 my process and type of molds in any essential) by meansof which suction may be applied to draw the particles of the liquid pulin close and regular contact with the sur ace of the mold at a stage ofthe sub- 0 mersion subsequent to the upward lifting of the mold, tosustain the wet film in contact, or to aid or modify the skilledmovements given by the operators hands that weave and interlace thefibers. being engaged in operating the mold, a bellows, pump or suchlike appliance operated by foot, is employed to actuate the suction.This auxiliary suction arrangement, comprises a fitment in the form of alever-cock, attached to preferably the right hand side of the mold. Thelever may be readily moved by the finger to open or close the suction. Anozzle is provided on the cock, at a convenient distance whereby themouth of the suction tube from the pump may be readily slipped on or offby the finger and thumb of the right hand, extension of the suction tubeto the permeable material being illustrated hereinafter.

The li uid pulp may be applied to the surface di the mold b dipping inthe vat as described in the ordinary hand mold, or alternatively this.object may be attained by dipping the base and spraying or pouring overthe liquid pulp to the outer surface of the mold all other conditionsbeing the same,.my process being proceeded with' as already andhereinafter described.

The wet film of paper is now transferred to ing and sizing, but as I amnot producing a flat sheet but an integral sheet with a required shapeor series of shapes raised upon its surface, the felts must correspondto those sha es. I therefore employ a felt or felts mol ed out of orwoven to "the required shape or shapes, to .form a casing or cover foreach shape. These felt casings are stretched upon and evenly attached toa correspondingly shaped wire frame of a size approximately "equal to myhand mold. The'wet film of paper of raised shape is couched on andwithin this specially formed felted frame and, on contact, will readilyadhere to the same and allow the hand mold The hands-zation ascontainers the felt for the purposes-of further drainto be removed. Theoperation of sizing follows that of transferring, and in order that inmy process these operations may be continuous for convenience of timeand method, I suspend the felted frame at a suitable distance above thehand mold, set the suction tube when that is being used at the top ofmold through the felt, or at another suitable part of the mold andproceed to form the layer of paper; thereafter release the suction,convey the hand mold with the contained wet film of paper, and the feltin position, to the sizing tub. After sizing and partly drying, the wetfilm has been thereby rendered suitable for handling as a. formed shapeof paper of oneintegral piece. The molded shape or shapes are trimmed orseparated from the entire piece so as to leave a flanged portion on thebase of each.

" In the further operations of surfacing and the like preparatory totheir complete finishing and with the object of their utiliand the. likefor example, I have produced by this process a number of shaped articlesas illustrated. The shapes which are in the form of a tray or filter(hereinafter described) are surfaced in the ordinary embossing pressbetween metal surfacing molds of the same shape as the molded articles.The shapes in the forms of cups, bottles and the like are surfacedbetween rollers and the edges of the top or bottom turned over andseamed by-means of a machine similar to that known in the sheet metaltrade. In the case of the bottle shape a formed disc of paper is joinedto form the bottom and to enable this operation to be done more readilyan adapter (as hereinafter described) is used, that expands to the sizerequired when placed inside the shape. The machines for these finishingoperations and the shapes in stages of completion are shown in theaccompanying drawings.

To render these articles waterproof and airproof they may be dipped inhot wax or other suitable proofing material for use as containers ofliquid such as milk.

In cases where additional strength or 'being unattached to the mold andke' t in position by means of a movable metal rame underneath thedeckle, as illustrated in the accompanying drawings.

portion of the side of the mold frame F.

Fig. 3 is a cross section of the mold as Fig. 1, at a, a, and B a crosssection at b, I). The deckle is shown at D andthe mold frame at F. Thepermeable face is indicated at 0 and the cross wires supporting the-moldface at c.

Fig. 4 Sheet 2 is a plan of the hand mold showing the deckle D andindicating the mold frame by the dotted lines. The permeable face isformed into one raised shape, represented at C. Fig. 5 is a View inperspective of the same mold showing the deckle D, and a portion of theside of the mold frame F. Fig. 6 is the mold as in Fig. 4 at a, a. Thede'ckle is shown at D and frame at F. The permeable face is indicated at0 and the cross wires supporting the mold face at e.

Fig. 7 Sheet 3 is an elevation of the mold aforementioned, showing thesuction attachment applied internally, S is the suction tube, M itsmouth. The lever and cock are represented at L and C, N is the nozzle,on which the suction tube is attached and O is the suction tube fromsuction pump (not shown). Fig. 8 is a cross section of the hand mold asin Fig. 7 showing the suction attachment S in cross section. is themouth, T a trap for water leakage, L the lever, C the cock, N thenozzle, and O the suction tube from suction pump. Fig. 9 is a crosssection of the same hand mold, but

with a raised shape in the form of a bottle B. This figure shows thesuction tube S ap-v plied externally. M' is the mouth in the form of ahollow cap of soft rubber. The suction tube is jointed at J, and theportion of tubing extending in a curve and may be moved in any 10 showsan alternative method of attaching the suction tube mouth M, over afixed noz- 4 represents a cross section of a similar mold to Fig. 6without the deckle or frame, the face of permeable material and itssupporting wires being attached to a metal frame F, and the interiorsurface being wholly covered with felt indicated at H. The gauze wire isshown at 0 and the supporting wires at 6. This figure represents thefelted frame. Fig. 12 is a similar felted frame having the 'felt uponthe outside surface as at H. These felted frames as shown in Figs. 11and 12 are for couching a cross section of r matically.

the deposited films in or upon the surfaces shown. I

Fig. 13 Sheets 4 and 6. The numbered objects viz: 1, 2, 3, 4 correspondto the same numbers as indicated on Fig. 1 Sheet 1, and represent thefinished articles in the forms respectively of a tray 1, a double orfolding tray 2 which has been formed by cutting away the flange of thearticle molded as shown at 2, 2 Fig. 1 except the portion thereofbetween the two tray-like shapes which is left to form a hinge. A filteris shown at 3, the articles 1 to 3 being for laboratory use for dryingand filtering, and a cross in relief 1, being an association of ideaswith the work. P represents a usual form of press for embossing and usedwith this process for surfacing and finishing the shaped articles. Fig.14 is a cross section of a hand mold as in Fig. 6 Sheet 2 showing across section of the aforesaid removable metal frame It and a detachablepermeable material. Fig. 15 is a View in perspective of the removablemetal frame R used as described in the process of producing reinforcedshaped articles. Fig. 16 represents the mold as at Fig. 1 1 without theremovable metal frame and after the deposited film and permeablematerial together are removed. Fig. 17 is a cross section of thepermeable material and deposited film combined and separated from themold frame. 0- is the permeable material and K the deposited filmoffibrous material.

Fig. 18 Sheet 5 represents at A two hollow rollers for compressing andsurfacing the molded shapes. Roller No. 1 the driver is fixed and isrevolved by 'a belt or gearing and is gas heated internally. Roller No.2 corresponds in shape to No. 1 without the bevelled part and is mountedin the frame, so as to be movable up or down and laterally in a wellknown manner as exemplified in a radial drill independently of No. 1that revolves it by contact. The spindle carrying roller No. 2 unlikethat of the drill does not revolve. The cup shape as example No. 1 Fig.20 is placed on roller No. 2 by hand or auto- The handle H by Which theroller 2 is operated is slid forward for contact and compression, theroller is next eased off slightly and by pressing the handle downwardsthe flanged portion is flattened. The flange is brought parallel withthe axis by a final movement at foot of the rollers. The shape thenreleased will appear at No. 2, Fig. 20.

Fig. 19 Sheet 5 are two mandrels Nos. 1

provided on their right hand ends with removable dies or formers maleand female by a hand agitation of t e and in order that the shapes maybe readily placed between these dies or removed, the upper spindle isarranged so that it may be moved upwards at the right hand end by alever H provided with a spring to throw the spindle back to its parallelposition with respect to the other spindle, on releasing the lever. Thecup shape 2 Fig. 29 is placed between these dies for the purpose ofturning in the flanged portion as in example 3, and again in another setof dies to finish the edge or rim of the cup shape as example 4 Fig. 20in which the turned over part has been compressed so as to .make theseam practically imperceptible.

Referring to Fig. 21 sheet 6 the bottle shapes Nos. 1, 2, 3, 4 aretreated between a set of rollers as Fig. 18 of a shape to suit theirform, the process being the same excepting that a flanged disc of paperis added at the stage of example No. 2 and the disc a placed inside theshape before turning over the edge, and the two edges or flanges placedbetween the dies, and turned over together to form the joint as inexample, 3 and further to finish as example 4 a flanged cap 6 or disc ofpaper 0 is provided to cover the mouth or opening for attachment by asuitable cement.

To'hold the flanged disc on to form the bottom of the bottle shape inposition between the dies to produce example 3, an adapter comprisingany known device such as a pair-of arms connected by links to a slidingcentral rod inside a tube, as shown at T, is provided for use within theshape during the operationand this is held by the hand, or carried in amovable carriage, in alignment with faces of the dies.

Claims:

1. The herein described process of making shaped articles consisting inapplying nonviscous fibrous pulp exteriorly of a recessed hollow formpremeable by the liquid of the pulp and having an open bottom, until thepulp reaches and barely covers the top portion of the form layin -.thefibers thereof mold while gradually raising the mold from a bath of saidpulp, whereby subatmospheric pressure is developed within the portionsof the mold projecting from the pulp, and the area of the form subjectedto said pressure is progressively increased, and transferring thearticle from the mold to an absorbent form adapted to receive same andconforming in contour to the mold.

2. The herein described process of making shaped articles consisting inapplying non-viscous fibrous pulp exteriorly of a form permeable by theliquid of the pulp, and having an open bottom, until the pulp reachesand barely covers the top portion of the form, developing a suctionwithin a progressively increasing portion of said mold, laying thefibers thereof by a hand'agitation of the mold, and transferring thearticle from the mold to an absorbent form adapted to receive same andconforming in contour to the mold. p

'3. The herein described process of making shaped articles consisting indipping the open base of a recessed mold having an open bottom and asurface permeable by the liquid contained in .paper pulp in a vatcontaining such pulp, spraying or pouring pulp over said mold, until thepulp reaches and barely covers the to portion of the mold laying thefibers of t e pul upon said mold by a hand agitation thereof graduallyraising said mold from the mass of pulp dura ing such agitation, wherebysubatmospheric pressure will be developed Within the mold and will beprogressively extended to increasing areas thereof, and transferring thearticle from the mold to an absorbent form adapted to receive same-andconforming in contour to the mold.

4. An apparatus for use in the manufacture of formed paper articlesconsisting in a movable hand mold having an open bottom comprising arigid wire frame support ing permeable material conforming to the shapeof the article to be made and having a movable upper frame.

5. In an apparatus for forming shaped paper articles, the combinationwith a recessed hollow form mold having a surface permeable to theliquid of the pulp and an open bottom, of a felt lined similarly andinversely shaped frame adapted to receive the article from said mold.

' 6. An apparatus for use in the manufacture of formed paper articlesconsisting in a movable hand mold having an open bottom comprising arigid wire frame supporting permeable material conforming to the shapeof the article to'be made and having a movable upper frame, saidpermeable material being separably connected to said frame, whereby itmay be retained in the article to reinforce same.

WILLIAM ROY.

